Alternative Materials for Infant

Mealtime ProductsBy: Sean Dunn, George Ferko,

Shannon Fitzpatrick, Ashley Kamauf,

Binay Patel, and Susan Sebelsky

Presenter : Shannon 1

Outline

• I. Company Background (Shannon)

• II. The Problem (Shannon)

• III. Materials Selection (Ashley)

• IV. Design Evolution (Sean)

• V. Testing (Binay and Susan)

• VI. Manufacturing (George)

• VII. Financials (Binay)

• VIII. Future Steps (Susan)

Background on Playtex

• Playtex Products, Inc. is a leading

manufacturer of feminine, skin, and infant care

products.

The Problem – Customer needs

Ceramic Microwave Plastic

Customer Needs

• Toxin-free• Affordable

• Aesthetically attractive• Sustainable• Eco-friendly

• Dishwasher safe• Microwavable

Currently, parents who use plastic dishes will heat the food on ceramic dishes first.

Mission Statement

• Our mission is to create a mealtime set that is:– microwave safe

– non-breakable

– free of harmful chemicals

• The set will:– implement the alternative materials that we have

researched

– provide a safer, more efficient way for parents to feed their 9-18 month old children

Alternative Materials

Bagasse

Polylactic acid

Cork

Bamboo

BagasseMaterial• All-natural fiber that is a byproduct

of the sugar cane refining process

Industry• A substitute for Styrofoam in the

production of disposable plates• Widely available from countries

such as the US, Brazil, and China

Our Testing/Evaluation• Passed drop testing• Passed stain testing after 1-3 cycles• Why not just use paper?

– Environmentally sound substitute for trees– It does not require bleaching, is highly recyclable,

and is also highly biodegradable

8Presenter : Binay

PLAMaterial• Made from corn or other starch based products• Thermoplastic polyester• Biodegrades in less than 90 days

Industry• Manufactured by blow molding,

injection molding, thermoforming,and direct extrusion

Our Testing/Evaluation• Passed drop test• Failed stain test (Low grade PLA)• Microwavable and dishwasher safe• FDA food safe

Presenter : Ashley 9

BambooMaterial• Very high sustainability• Imported from China and Vietnam

Industry• Processing

– Stripping– Sugar and moisture removed – Pressed with water – Laminated into bulk shape– Finishing

Our Testing/Evaluation• Breakage in drop testing has led to

investigation of different constructions• Staining variability• Bite test results exceeding CPSC requirements

Presenter : George 10

CorkMaterial• Harvested from trees• Renewable, recyclable, and reusable• Biodegradable

Industry• Boiled to remove impurities• High elasticity and compressible

Our Testing/Evaluation• Passed drop test• Passed stain test• Microwavable and dishwasher safe• FDA food safe

Presenter : Sean 11

Concept Generation

Presenter : Susan 12

HOLD FOOD CLEAN FOOD HOLDER HEAT FOOD HOLDING UTENSILS KEEP HOLDERS STRUCTURE OF ENJOYABILITY/FUN STORAGE OF HOLDER

STATIONARY FOOD

plate/bowl dishwasher microwave n-shaped magnets compartments colorful switch containers

tray hand washing stove top motor powered tray with snap in slots connectable bowls flashing lights lids

hollowed out fruit throw away exothermic reaction interchangable head suction cups reward on the bottom music removable bag that ziplocs

fishbowl removable surface toaster oven/toaster squirter system sticky surface rotating system cartoon characters throw it out

box compressed air lid=microwave glove for eating with hands friction small portions glitter nesting bowls/plates

basin high pressure water warm plate bracelet adhesive layers interactive buttons stackability

boot bleach rotation legos outer ring placemat with section themed set foldable

sack ammonia nuclear skewer to poke food weights pyramid give you compliments shrinkable

animal shell brushes (wire/plastic) hamster lock in to plate wider bottom cutout shapes prize at the bottom utensils could pop into back of plate

syringe gritty cleansers rotation grips rubbery bottom maze tv on the surface collapsable

edible container windshield wiper light magnets velcro adjustable compartments stickers blow up/inflatable

bowl/plate in one hoover vacuum heat lamp end wider sand weighing it down hot/cold compartments fun shapes plate as lid for bowl

water heater tongue blow dryer moldable handles interlocking blocks rearrangable parts transformers interlocking

bag gravity car exhaust resting holder hooks over the table v-shaped bowl live fish/sea animals inside magnetic to mat

hand sprinkler dragon fire flat/curved rubber mats interlocking parts legos interlocking blocks

levitation toothbrush double boiler looped ends textured mobile train set roll up

mind bacteria/microorganism electrical current adhesion to hands placemat with slots solar system plates transparent hooks

water suspension chemical solution laser memory foam handles suction tower or containers radio suction cups

vacuum self-cleaning thermo-chemical reaction over fingers brakes pumping mechanism tell a story vase (decorative)

bag turbo spin cycle grill elastic to attach to set pulley system automated dispenser slip and slide stick to the ceiling

air suspension (wind) steam cleaning pig roast style mechnical wings necklace insulation curly doctor's office thing flatten

fire truck only rinsing solar panel gel filled handle fun tack catapult sports goal in mouth invisibility

police car oxidation sun suction poster mounts orbiting catapult levitation to the storage location

space shuttle loofah hot plate duct tape glue conveyor belt animal faces twisting mechanism (like laundry)

helmet water gun heating sleeve feeding tube static electricity suspended in gelatin disney princess hangability

catapult wipes open flame hold with mind vacuum seal cars/trucks

water heater car wash bunsen burner train shaped duct tape fish/Nemo

force field crock pot clamp astro-turf body

body heat vacuum food themed

THINGS TO AVOID bake/broil baseball/sports

90 degree angles oil/gas color changing

small gaps photo inserts on the bottom

First Prototype

– Plate

• Decreased volume – Less material

– Lower cost

• Large diameter– Increases surface area for easier

eating

• Deeper compartments– Holds more food

• Higher edges to prevent spilling

Design Improvements

Second Prototype

– Plate Holder

• 36% wider to provide stability

• 136% higher to accommodate more plates and prevent spills

• Modifications to finger holes

Design Improvements

Final Design

Ergonomics – Unique Features•Plate holder

•Finger holes to make it easier for parents to remove plates

•Unique base made specifically for Playtex plate, giving the system more stability

Ergonomics – Unique Features

• Fork/Spoon handle

• Flexible n-shaped handle makes holding fork/spoon easier for infants

• Plate

• Inclined bottom allows infants to easily scoop food from plate surface

Design Testing

• What prototypes were tested?

– Plate

• Compared to a similar competitor's product (Boon)

– Plate holder

• What was tested?

– Notch Scoopability

– Tip Seep

– Slide Spill

Physical Testing Results

• Notch

• Tip

• Slide

Physical Testing Results

• Scoop

• Seep

• Spill

Focus Group – Results

Develop protocol

Discussion guide Post-discussion

Recruit mothers

Create goalsç

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NovemberOctober December

Background• Playtex’s focus groups, also referred to as “Mom groups,” are composed

of 15-20 pre-selected mothers

Goals• To find out how mothers feel about the implementation of natural

materials in mealtime sets • Receive reactions to the plate holder design and how it can be

improved

Focus Group 1 Poll Results

Focus Group 2 Poll Results

Microwavable Materials

Bamboo1 Mother (8%)

Bagasse12 Mothers (92%)

Microwave Dishwasher Serving

Bamboo 1 0 3

Bagasse 5 0 3

Cork 0 0 0

PLA 0 0 0

Stainless Steel 0 6 0

Silicone 0 0 0

Microwave Dishwasher Serving

Bamboo 0 0 0

Bagasse 6 0 5

Cork 0 0 0

PLA 0 0 3

Stainless Steel 0 4 2

Silicone 0 1 0

Focus Group – Results

“It’s really exciting that you’re developing these products – the natural ones” – Mom from Group 1

Focus Group – Results

• 13 out of 13 moms do not heat plastic in the microwave when feeding their children

– The mothers like bagasse because it feels natural, is durable, and will not get too hot after heating

• When presented with the plate holder, one mother stated “the marriage of materials works”

• The most attractive design features were:

– bagasse suction of the holder

– ease of use disposable option

Manufacturing

PLA

Natureworks(Resin Manufacturer)FOB: Blair, Nebraska

Cereplast(Resin Distributer and Injection

Molding/Thermoforming)FOB: Blair, Nebraska

Playtex(Quality Control and Injection Molding or Assembly)

Manufacturing

Sugar Cane Bagasse

Brazil Biomass and Renewable Energy Exports S.A.

(Bagasse Pellet Manufacturer)FOB: Paranaguá, Brazil

BioPlanet(Pulping and Plate/Bowl Pressing)Large Order FOB: Mexico or China

Playtex(Quality Control and Assembly)

Bill of Materials# of

Parts Part Title Material Request

Build vs

Buy Source

Labor &

Mat CostSpecifications

1 Holder Body Mold

Polylactic Acid/Cereplast

Hybrid Resins

Inner Diameter = 6 in, Out

Diameter = 7.5 in, Inner Hole =

1.5 in, Height = 2 in, Inter Lining

Perforated every 1/32 in Buy CEREPLAST,INC $1.19

2 Rubber Ring Bottom Rubber Ring Diameter = 6 in. Buy CEREPLAST,INC $0.25

3 Adhesive Resin Amount = 0.5 ounces Buy LHS Enterprises $0.10

4

Bagasse

Compartment Plate

Insert Bagasse

Diameter = 6 in, 3 Check

Shaped Cross Section

Compartments, Height = .60 in Buy Brazil Biomax $0.26

5 Bagasse Bowl Insert Bagasse Diameter = 6 in, Height = 2.5 in Buy Brazil Biomax $0.24

6 Outer Mold- Fork

Polylactic Acid/Cereplast

Hybrid Resins Length = 4.5in Buy CEREPLAST,INC $0.33

7 Outer Mold- Spoon

Polylactic Acid/Cereplast

Hybrid Resins Length = 4.5 in Buy CEREPLAST,INC $0.30

8 Inner Flex Stripe Polyethene Length = 4 in Buy

Zhejiang Yulong

International Trading

Company Ltd $0.25

TOTAL $2.92

Financials

Cash Flow Sensitivity to Assumptions

-10000

0

10000

20000

30000

40000

50000

60000

70000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Base Case

Worst Case

Best Case

Financial Forecast

Parameters Base Case

Net Present Value $12,727,000

Break Even Period 11 Quarters

Break Even Amount $622,500

Break Even Units 708,750

IRR 81.9%

Tornado Diagram

($10,000.00) ($5,000.00) $0.00 $5,000.00 $10,000.00 $15,000.00

Number of Units Made Per Year

Unit Cost Per Unit Sold (in Dollars, from Bill of Materials)

Marketing & Support Costs Per Year (People Time, Ads, Travel, Trade Shows, Office Support

Net Present Value Under High, Low & Base Assumptions

Base Case

Best Case

Worst Case

Future Steps– Next Generation Prototype

• Changes based on Mom Group

• Changes based on new physical testing of desired features

• Incorporation of the Playtex prototype into ours

– “Mom Group” of next generation prototype• Design updated based on

final results• Large number of

participants (~100)• Smaller group sizes per

session

– Marketing Strategy Development• Emphasize “green” product• Emphasize ease of use and

safety

– Manufacturing Ramp up• Employ suggested foreign

producers• Assemble small inventory

– Consumer Testing

Summary

Acknowledgements

• Our company sponsors and customer research team at Playtex

– Jeremy Giese

– Adriana Kliegman

– Cathy Durden

– Frank Yang

• Our faculty advisors

– Prof. Lori Herz

– Prof. Todd Watkins

• The IPD staff

– John Ochs

– Lisa Getzler-Linn

– Bobbi Spain

• Lehigh staff

– Devin Tyman

– Prof. Richard Vinci

– Prof. David Angstadt